Pap system blower

ABSTRACT

A blower includes a housing including an inlet and an outlet, a bearing-housing structure provided to the housing and adapted to rotatably support a rotor, a motor provided to the bearing-housing structure and adapted to drive the rotor, and an impeller provided to the rotor. The bearing-housing structure includes a bearing shaft having a bearing surface that rotatably supports the rotor. The bearing shaft provides only a single bearing of the non-ball bearing type for the rotor.

CROSS-REFERENCE TO APPLICATIONS

This application is a continuation of U.S. application Ser. No.16/798,483, filed Feb. 24, 2020, which is a continuation of U.S.application Ser. No. 14/112,072, filed Oct. 16, 2013, now U.S. Pat. No.10,576,227, which is the U.S. national phase of InternationalApplication No. PCT/US2012/034017 filed 18 Apr. 2012 which designatedthe U.S. and claims the benefit of U.S. Provisional Application Nos.61/457,526, filed Apr. 18, 2011, and 61/630,920, filed Dec. 22, 2011,each of which is incorporated herein by reference in its entirety.

Also, PCT Application No. PCT/AU2010/001106, filed Aug. 27, 2010, isincorporated herein by reference in its entirety.

FIELD OF TECHNOLOGY

The present technology relates to Positive Airway Pressure (PAP) systemsand/or methods of use for treatment, e.g., of Sleep Disordered Breathing(SDB) with Continuous Positive Airway Pressure (CPAP) or Non-InvasivePositive Pressure Ventilation (NIPPV). More specifically, the presenttechnology relates to blowers for PAP systems.

BACKGROUND OF TECHNOLOGY

Examples of head mounted blowers, wearable CPAP, or portable CPAP areknown in the art. For example, see U.S. Patent Application Publications2006/0237013 A1 and 2009/0320842 A1, each incorporated herein byreference in its entirety, and the BreatheX™ system.

SUMMARY OF TECHNOLOGY

Certain examples of the present technology relate to minimalistic CPAPsystems, methods of use, and devices structured to at least reduceimpact on the patient.

Certain examples of the present technology relate to patient interfacesthat incorporates a relatively small or miniature blower.

Certain examples of the present technology relate to a blower that has avery small size, low cost and/or ease of assembly.

One aspect of the present technology relates to a new small blower foruse in a PAP delivery unit that is designed to provide pressure supportto a user. For example, the PAP delivery unit may provide low levelpressure support of approximately 1-8 cm H₂O, e.g., operated at a speedof approximately 15,000 rpm and/or flow approximately 70 L/min. However,pressure support at higher levels, such as 1-25 cm H₂O, may also beprovided.

Certain examples of the present technology relate to a blower in whichthe inlet and the outlet are axially aligned with an axis of the blower.

Certain examples of the present technology relate to a blower in whichthe housing includes an axial aligned inlet and an outlet that istangential to the inlet.

Another aspect of the present technology relates to a blower that doesnot use or require ball bearings. Instead, the blower may include acentral bearing structure, e.g., formed at least in part out of a lowfriction lubricious material such as sintered bronze, an engineeredplastic material, e.g., a polyamide-imide resin such as a Torlon™,and/or other very low friction materials and/or other materials coatedwith a low friction material. The bearing may have a large bearingsurface that surrounds a rotor or shaft, e.g., a highly polished shaft.The central bearing structure may include a radial sleeve bearingportion and a thrust bearing portion. The thrust bearing portion mayutilize low friction materials, e.g., as described above.

Another aspect of the present technology relates to a blower thatincludes or requires only a single bearing structure including a radialbearing portion and a thrust bearing portion, which may assist inreducing the height of the blower. A thrust load may be provided on atop surface of the bearing. The radial bearing portion may be configuredas a sleeve bearing along the surface of the shaft. As there is only asingle bearing, the motor only requires balancing in one plane and nottwo planes.

Another aspect of the present technology relates to a disk-likebearing-housing structure to provide support to a rotor or shaft. Thedisk part of the bearing-housing structure may also provide a shieldingfunction to prevent blade pass tonal noise from being generated fromde-swirling vanes when an impeller spins. The top surface of thebearing-housing structure surrounding the shaft and adjacent the rotorcap may perform the bearing function by providing a radial surface alongthe shaft and a thrust surface to allow the parts to rotate. The statorcomponents of the motor may be attached to the bearing-housingstructure.

Another aspect of the present technology relates to a rotor retentiondesign in which the rotor and/or rotor assembly are prevented fromlifting off or separating from the blower housing.

Another aspect of the present technology relates to a bearing greaseretention design within the bearing-housing structure to provide areservoir of grease for supply to the thrust surface.

Another aspect of the present technology relates to a nested design inwhich the motor (stator component, fixed magnet and/or rotor cap) are atleast partially nested within the impeller to reduce the size of theblower. The impeller may be directly molded or over-molded onto therotor cap.

Another aspect of the present technology relates to an impeller having arotor portion integrated therein. The conjoined impeller and rotor maycomprise at least some ferrous material, such as magnetic steel, thatprovides a path for magnetic flux of a permanent magnet or magnets topass therethrough, to cause rotation of the impeller through theinteraction of the flux with that of a stator, e.g., a commutated motorstator.

Another aspect of the present technology relates to an impeller that maybe retained on a rotor or shaft by a magnetic retention between themagnet coupled to the inner surface of a rotor cap and a statorcomponent. There is no required fastening of the impeller to the rotoror shaft.

Another aspect of the present technology relates to blades of theimpeller that curve in towards the hub having a slight S-like shape. Theshape may be designed to reduce vortex shedding.

Another aspect of the present technology relates to an impeller. Theimpeller may be of the double shrouded type or an alternating shroudimpeller as the shrouds may not fully cover the top and/or bottomsurfaces of the impeller blades. An alternative is to use a bottomsubstantially fully shrouded impeller to help address an issue of theimpeller lifting off the rotor or shaft in use.

Certain examples of the present technology relate to CPAP systems,methods of use and devices structured to at least reduce size and bulk,reduce vibrations, reduce generated noise or combinations thereof.

Certain examples of the present technology relate to small CPAP devicesconfigured to supply pressurized breathable gas (e.g., air) in a mannersuitable for treatment of sleep apneas and/or snoring.

Certain examples of the present technology relate to PAP systemsincluding a patient interface including sealing arrangement adapted toform a seal with the patient's nose and/or mouth and headgear to supportthe sealing arrangement in position on the patient's head. A blower isstructured to generate a supply of pressurized air. The blower issupported by the patient interface on the patient's head (e.g., withinor formed as part of the headgear or cushion (e.g., integrated with anozzle or nozzles) and in communication with the patient interface. Theheadgear may form one or more ducts to communicate pressurized air fromthe blower to a breathing cavity defined by the sealing arrangement.Alternatively, a separate tube may be provided to communicatepressurized air from the blower to the sealing arrangement.

In certain examples, PAP systems are disclosed that may be configured toprovide a minimal visual footprint in use. The flow generator of suchPAP systems comprises at least one blower and/or at least one blowerhousing and are in air communication with a patient interface. Inaddition, these PAP systems may include other structural elements (forexample, but not limited, to headgear, shoulder-type harnesses,pendant-type arrangements, articles of clothing, straps or bandarrangements or combinations thereof) resulting in PAP systems that maybe portable, carried by the patient, used for travel, mask mounted, headmounted, located within or beside a pillow, configured for attachment tobed, configured for attachment to a headboard, configured for attachmentto a chair or wheelchair, or combinations thereof.

In certain examples, the PAP system may be used in a hygiene device tofilter air. The hygiene device may provide clean or purified, filteredair to a user. The filtered air may be pressurized. The hygiene devicewould include a filter designed to remove particulate matter from theair to deliver the purified air to the user.

In certain examples, the blower may include a width of about 60-65 mm,e.g., 62.8 mm, and a height of about 20-25 mm, e.g., 23.2 mm.

Another aspect of the present technology relates to a blower including ahousing including an inlet and an outlet, a bearing-housing structureprovided to the housing and adapted to rotatably support a rotor, amotor provided to the bearing-housing structure and adapted to drive therotor, and an impeller provided to the rotor. The bearing-housingstructure includes a bearing shaft having a bearing surface thatrotatably supports the rotor. The bearing shaft provides only a singlebearing structure of the non-ball bearing type for the rotor.

Another aspect of the present technology relates to a blower including ahousing including an inlet and an outlet, a bearing-housing structureprovided to the housing and adapted to rotatably support a rotor, amotor provided to the bearing-housing structure and adapted to drive therotor, and an impeller provided to the rotor, wherein the motor is atleast partially nested within the impeller.

Another aspect of the present technology relates to a blower including ahousing including an inlet and an outlet, a bearing-housing structureprovided to the housing and adapted to rotatably support a rotor, amotor provided to the bearing-housing structure and adapted to drive therotor, and an impeller provided to the rotor, wherein the impeller isretained on the rotor by magnetic retention.

Another aspect of the present technology relates to a blower including ahousing including an inlet and an outlet, a bearing-housing structureprovided to the housing and adapted to rotatably support a rotor, amotor provided to the bearing-housing structure and adapted to drive therotor, and an impeller provided to the rotor, wherein thebearing-housing structure is constructed of or coated with a lowfriction material or a lubricous material. The lubricous materialincluding sintered bronze, an engineered plastic material, e.g., apolyamide-imide resin such as a Torlon™ and/or other very low frictionmaterials. The bearing-housing structure may be constructed of acombination of materials including a lubricous material or a materialhaving a very low coefficient of friction. For example, a firstmaterial, such as an aluminum, steel, brass, bronze or other metal orplastic, may be coated with a lubricous material or material having avery low coefficient of friction such as a ceramic based or a nickelbased coating material. In certain examples, the coating may be appliedonly to the critical wear surfaces of the bearing-housing such as theshaft receiving surface. Alternatively or additionally, the shaft may becoated with such materials to reduce friction.

Another aspect of the present technology relates to a blower including ahousing including an inlet and an outlet, a bearing-housing structureprovided to the housing and adapted to rotatably support a rotor, amotor provided to the bearing-housing structure and adapted to drive therotor, and an impeller provided to the rotor, wherein thebearing-housing structure includes a bearing shaft that rotatablysupports the rotor and an annular disk that substantially aligns with orextends radially beyond the outer edge of the impeller to provide ashielding function.

Another aspect of the present technology relates to a blower including ahousing including an inlet and an outlet, a bearing-housing structureprovided to the housing and adapted to rotatably support a rotor, amotor provided to the bearing-housing structure and adapted to drive therotor, and an impeller provided to the rotor. The bearing-housingstructure includes a bearing shaft having a bearing surface thatrotatably supports the rotor. The motor includes a stator assembly, amagnet, and a rotor cap. The rotor cap includes an interior surface thatsupports the magnet and an exterior surface that supports the impeller.The rotor cap is engaged with the rotor such that the stator assemblyacts on the magnet to cause spinning movement of the rotor cap and hencethe impeller in use.

In an example, a plurality of pre-swirl inlet vanes may be provided to atop cover of the housing to direct airflow towards the inlet. Apre-swirl cover may be provided to cover the pre-swirl vanes.

In an example, the bearing-housing structure may be coupled to a bottomcover of the housing via a snap feature or a screw arrangement.

In an example, the bearing-housing structure includes an annular diskthat substantially aligns with or extends radially beyond the outer edgeof the impeller to provide a shielding function. In an example, thebearing shaft and the disk include a split configuration in which thebearing shaft and the disk are separate components.

Another aspect of the present technology relates to a blower including ahousing including an inlet and an outlet, a bearing-housing structureprovided to the housing and adapted to rotatably support a rotor, amotor provided to the bearing-housing structure and adapted to drive therotor, and an impeller provided to the rotor. The bearing-housingstructure includes a housing part and a bearing cartridge provided tothe housing part. The bearing cartridge includes a tubular sleeve andtwo spaced-apart bearings supported within the sleeve to support therotor.

Another aspect of the present technology relates to a blower including ahousing including an inlet and an outlet, a motor provided to thehousing and adapted to drive a rotor, an impeller provided to the rotor,and an inlet cap provided to the inlet of the housing. The inlet cap isstructured to occlude or block at least a central portion of the inlet.

Other examples, aspects, features, and/or advantages of this technologywill become apparent from the following detailed description when takenin conjunction with the accompanying drawings, which are a part of thisdisclosure and which illustrate, by way of example, principles of thedisclosed technology.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings facilitate an understanding of the variousexamples of this technology. In such drawings:

FIG. 1 is a perspective view of a headworn PAP system according to anexample of the present technology on a model user's head;

FIG. 2 is an exploded view of a blower according to an example of thepresent technology;

FIG. 3 is a cross-sectional view of the blower of FIG. 2 ;

FIG. 4 is an isometric cross-sectional view of the blower of FIG. 2 ;

FIG. 5 is an isometric cross-sectional view like FIG. 4 , but withoutthe top cover;

FIG. 6 is a perspective view of a top cover of the blower of FIG. 2 ;

FIG. 7 is a reverse perspective view of the top cover of FIG. 6 ;

FIG. 8 is a perspective view of a bottom cover of the blower of FIG. 2 ;

FIG. 9 is a reverse perspective view of the bottom cover of FIG. 8 ;

FIG. 10 is a perspective view of a bearing-housing structure of theblower of FIG. 2 ;

FIG. 11 is a reverse perspective view of the bearing-housing structureof FIG. 10 ;

FIG. 12 is a perspective view of a rotor cup of the blower of FIG. 2 ;

FIG. 13 is a cross-sectional view of the rotor cup of FIG. 12 ;

FIG. 14 is a perspective view of an impeller of the blower of FIG. 2 ;

FIG. 15 is a reverse perspective view of the impeller of FIG. 14 ;

FIG. 16 is a side view of the blower of FIG. 2 showing exemplarydimensions according to an example of the present technology;

FIG. 17 is a perspective view of a stator core and slotliners accordingto an example of the present technology;

FIG. 18 is a cross-section view of the stator core and slotliners ofFIG. 17 ;

FIG. 19 is a perspective view of a blower including a over-top retentionarm according to an example of the present technology;

FIG. 20 is an exploded view of a rotor cap and bearing-housing structureincluding mating features according to an example of the presenttechnology;

FIG. 21 is a cross-sectional view of the rotor cap and bearing-housingstructure of FIG. 20 ;

FIG. 22 is a cross-sectional view of a rotor cap and bearing-housingstructure including mating features according to another example of thepresent technology;

FIG. 23 is a cross-sectional view of a rotor cap and bearing-housingstructure including mating features according to another example of thepresent technology;

FIG. 24 is a cross-sectional view of a rotor cap and bearing-housingstructure including mating features according to another example of thepresent technology;

FIG. 25 is a cross-sectional view of a rotor cap and bearing-housingstructure including mating features according to another example of thepresent technology;

FIG. 26 is a cross-sectional view of a rotor cap and bearing-housingstructure including mating features according to another example of thepresent technology;

FIG. 27 is a plan view of the rotor cap of FIG. 26 ;

FIG. 28 is a cross-sectional view of a blower including a rotor with aretention flange according to an example of the present technology;

FIG. 29 is a cross-sectional view of a blower including a pre-swirlcover according to an example of the present technology;

FIGS. 30 to 32 are cross-sectional views showing a screw threadarrangement to couple the rotor cap to the bearing-housing structureaccording to an example of the present technology;

FIGS. 33 to 35 show various views of a bottom cover with de-swirlingvanes according to an example of the present technology;

FIGS. 36 to 38 show various views of a blower with pre-swirl inlet vanesand a pre-swirl cover according to an example of the present technology;

FIG. 39 is a cross-sectional view showing a bearing-housing structurewith a split configuration according to an example of the presenttechnology;

FIG. 40 is a cross-sectional view showing a bearing-housing structurewith a split configuration according to another example of the presenttechnology;

FIGS. 41 and 42 are a cross-sectional views showing a bearing-housingstructure with a split configuration according to another example of thepresent technology;

FIG. 43 is a cross-sectional view showing a bearing-housing structurewith a split configuration according to another example of the presenttechnology;

FIG. 44 is a cross-sectional view of a blower showing motor wire routingand PCB mounting according to an example of the present technology;

FIG. 45 is a cross-sectional view showing a bearing-housing structurewith a split configuration according to another example of the presenttechnology;

FIG. 46 is a cross-sectional view showing a bearing-housing structurecoupled to vanes of the bottom cover according to an example of thepresent technology;

FIG. 47 is a cross-sectional view showing a bearing-housing structurecoupled to vanes of the bottom cover according to another example of thepresent technology;

FIG. 48 is a cross-sectional view of a blower with elastomeric materialbetween the bearing-housing structure and the bottom cover according toan example of the present technology;

FIGS. 49 and 50 are cross-sectional views showing a bearing-housingstructure coupled to the bottom cover by a fastener according to anexample of the present technology;

FIGS. 51 and 52 are various views of the fastener of FIGS. 49 and 50 ;

FIG. 53 is a cross-sectional view showing a bearing-housing structurecoupled to the bottom cover according to another example of the presenttechnology;

FIG. 54 is a cross-sectional view showing a bearing-housing structurecoupled to the bottom cover according to another example of the presenttechnology;

FIGS. 55 to 65 are cross-sectional views showing a snap feature toattach the bearing-housing structure to the bottom cover according toalternative examples of the present technology;

FIG. 66 is a cross-sectional view showing a bearing-housing structurecoupled to the bottom cover by a screw arrangement according to anexample of the present technology;

FIG. 67 is a cross-sectional view showing a bearing-housing structurecoupled to the bottom cover by a screw arrangement according to anotherexample of the present technology;

FIG. 68 is a cross-sectional view showing a bearing-housing structurecoupled to the bottom cover by an integrated screw arrangement accordingto an example of the present technology;

FIGS. 69 and 70 are various views of a bearing-housing structureincluding a reservoir and channels to retain lubricant according to anexample of the present technology;

FIGS. 71 to 74 are various views of a bearing-housing structureincluding a lubricant reservoir according to an example of the presenttechnology;

FIGS. 75 to 79 are various views of a bearing-housing structureincluding recessed channels for lubricant according to an example of thepresent technology;

FIGS. 80 and 81 are plan views of recessed channels for abearing-housing structure according to alternative examples of thepresent technology;

FIGS. 82 and 83 show hydrodynamic pressure concentration provided byrecessed channels for a bearing-housing structure according to anexample of the present technology;

FIGS. 84 to 89 are various views of a bearing-housing structureincluding an annular recessed channel for lubricant according to anexample of the present technology;

FIG. 90 is a schematic view of a bearing shaft with a trilobeconfiguration according to an example of the present technology;

FIG. 91 is a cross-sectional view of a blower including a retaining ringto retain lubricant according to an example of the present technology;

FIG. 92 is a cross-sectional view of a blower including abearing-housing structure having structure to retain lubricant accordingto an example of the present technology;

FIGS. 93 and 94 show an impeller an impeller blade according to anexample of the present technology;

FIGS. 95 and 96 show an impeller and an impeller blade according toanother example of the present technology;

FIGS. 97 and 98 show an impeller and an impeller blade according toanother example of the present technology;

FIG. 99 is a cross-sectional view of a blower including an internalrotor configuration according to an example of the present technology;

FIG. 100 is a cross-sectional view of a blower including an axialconfiguration according to an example of the present technology;

FIGS. 101 and 102 are various views of a bottom cover includingde-swirling vanes according to an example of the present technology;

FIGS. 103 and 104 are various views of a top cover with pre-swirl vanesaccording to an example of the present technology;

FIGS. 105 to 107 are various views of a top cover with pre-swirl vanesand a pre-swirl cover according to an example of the present technology;

FIG. 108 is a cross-sectional view of a rotor cap and impellerintegrally formed as a one-piece structure according to an example ofthe present technology;

FIG. 109 is a cross-sectional view of a blower according to anotherexample of the present technology;

FIG. 110 is an enlarged cross-sectional view of a portion of the blowerof FIG. 109 ;

FIG. 111 is a cross-sectional view of a portion of a blower according toanother example of the present technology;

FIG. 112 is a cross-sectional view of a bearing cartridge according toan example of the present technology;

FIG. 113 shows an impeller according to another example of the presenttechnology;

FIG. 114 shows an impeller according to another example of the presenttechnology;

FIG. 115 shows an impeller according to another example of the presenttechnology;

FIGS. 116 to 119 show various views of a blower including an inlet capaccording to an example of the present technology;

FIG. 120 is a perspective view of a top cover for a blower including aninlet cap according to an example of the present technology;

FIG. 121 is a perspective view of a top cover for a blower including aninlet cap according to another example of the present technology;

FIG. 122 is a perspective view of a top cover for a blower including aninlet cap according to another example of the present technology;

FIG. 123 is a perspective view of a top cover for a blower including aninlet cap according to another example of the present technology;

FIG. 124 is another cross-sectional view of the blower shown in FIGS.116 to 119 ;

FIGS. 125 to 127 show alternative views of the blower of FIG. 109 ;

FIGS. 128 to 131 show various views of a blower according to anotherexample of the present technology;

FIGS. 132 to 138 show various views of a blower according to anotherexample of the present technology;

FIGS. 139 to 142 show various views of a blower according to anotherexample of the present technology;

FIG. 143 is a cross-sectional view of a blower according to anotherexample of the present technology;

FIG. 144 is a cross-sectional view of a blower according to anotherexample of the present technology;

FIG. 145 is a cross-sectional view of a blower according to anotherexample of the present technology;

FIG. 146 is a cross-sectional view of a blower according to anotherexample of the present technology;

FIG. 147 is a cross-sectional view of a blower according to anotherexample of the present technology;

FIG. 148 is a cross-sectional view of a blower according to anotherexample of the present technology;

FIGS. 149 and 150 show a blower mounted within the casing of a PAPdevice according to an example of the present technology; and

FIG. 151 is a cross-sectional view of a blower according to anotherexample of the present technology.

DETAILED DESCRIPTION OF ILLUSTRATED EXAMPLES

The following description is provided in relation to several examples(most of which are illustrated, some of which may not) which may sharecommon characteristics and features. It is to be understood that one ormore features of any one example may be combinable with one or morefeatures of the other examples. In addition, any single feature orcombination of features in any example or examples may constitutepatentable subject matter.

In this specification, the word “comprising” is to be understood in its“open” sense, that is, in the sense of “including”, and thus not limitedto its “closed” sense, that is the sense of “consisting only of”. Acorresponding meaning is to be attributed to the corresponding words“comprise”, “comprised” and “comprises” where they appear.

The term “air” will be taken to include breathable gases, for exampleair with supplemental oxygen.

The subject headings used in the detailed description are included onlyfor the ease of reference of the reader and should not be used to limitthe subject matter found throughout the disclosure or the claims. Thesubject headings should not be used in construing the scope of theclaims or the claim limitations.

PAP System

A PAP system (e.g., CPAP system) typically includes a PAP device(including a blower for generating air at positive pressure), an airdelivery conduit (also referred to as a tube or tubing), and a patientinterface. In use, the PAP device generates a supply of pressurized air(e.g., 2-30 cm H₂O) that is delivered to the patient interface via theair delivery conduit. The patient interface or mask may have suitableconfigurations as is known in the art, e.g., full-face mask, nasal mask,oro-nasal mask, mouth mask, nasal prongs, nasal cannula, etc. Also,headgear may be utilized to comfortably support the patient interface ina desired position on the patient's face.

Certain examples relate to PAP systems in which the PAP device or bloweris adapted to be worn on the patient's head, is built into orincorporated into the patient interface or mask, is wearable or carriedby the patient, is portable, is reduced in size or combinations thereof.In certain examples, the blower may be of the types described inInternational Application PCT/AU2010/001031, filed Aug. 11, 2010,entitled “Single Stage, Axial Symmetric Blower and Portable Ventilator,”and/or International Application PCT/AU2010/001106, filed Aug. 27, 2010,entitled “PAP system,” each of which is incorporated herein by referencein its entirety.

For example, FIG. 1 illustrates a headworn PAP system 10 including PAPdevice or blower 20, a patient interface or mask 30 (e.g., nasal mask),and an outlet tube 40 that interconnects the patient interface and theblower. Headgear 50 secures the blower and patient interface in positionon the patient's head in use. However, the PAP system may be configuredin other arrangements such as in or beside a pillow, in a scarf-likearrangement, incorporated into clothing, attached to a bed or bed head,etc., or in a more conventional PAP device configured to be located on asurface near a bedside similar to the ResMed™ S9™ CPAP system.

In certain examples, the PAP system may be used as a hygiene device topurify the incoming air. A filter may be present at the air inlet of thedevice to filter out particulate matter or impurities in the incomingair to deliver purified or filtered air to the user.

Blower

FIGS. 2 to 16 illustrate a single-stage blower 100 according to anexample of the present technology (e.g., blower 100 may be provided asblower 20 in the PAP system of FIG. 1 ). The blower provides anarrangement that is very small in size, low cost, compact, lightweight,and provides ease of assembly, e.g., for use in a small wearable PAPsystem. In an example, the blower may be structured to providepressurized air up to about 8 cmH₂O (e.g., a maximum of up to about 4-8cmH₂O, e.g., 4 cmH₂O, 5 cmH₂O, 6 cmH₂O, 7 cmH₂O, or 8 cmH₂O), which maybe suitable for mild forms of sleep apnea or for treatment of snoring)and be run at a speed of approximately 15,000 rpm and flow approximately60-70 L/min. In another example, the blower may be structured to providepressurized air at higher pressures such as about 1-25 cmH₂O and higherflows above 70 L/min such as up to approximately 90-120 L/min. Inanother example, the blower may include a multiple stage design, e.g.,two or more impellers. In such a multiple stage design, the blower maybe capable of providing higher levels of pressurized air of about 1-30cmH₂O and higher flow rates of up to approximately 140 L/min. However, askilled addressee would understand that other motor speeds, pressuresand flows may be used.

As illustrated, the blower 100 includes a housing or cover 120 with atop housing part or top cover 122 and a bottom housing part or bottomcover 124, a bearing-housing structure 130 (also referred to as acentral bearing structure), a motor 140 (including a stator assembly orstator component 145, a magnet 150, and a rotor cup or cap 160) providedto the bearing-housing structure and adapted to drive a rotatable shaftor rotor 170, and an impeller 180 coupled to the rotor cap 160. Therotor cap 160 is coupled to an end portion of the rotor 170 and togetherwith the magnet 150 may be referred to as the rotor assembly. In thisarrangement, the motor has an outer rotor configuration to rotate theimpeller 180. This arrangement also allows the motor components to atleast be partially nested within the impeller providing a lower profileblower.

In an alternative arrangement, not shown, the motor may include an innerrotor configuration wherein the magnet 150 may be coupled to the rotor170 and impeller 180 is coupled to an end portion of the shaft or rotor170. In such an arrangement, the impeller may be located above or aroundthe motor components. FIG. 99 illustrates an internal rotorconfiguration in which the rotor cap 160 includes an inner wall 160-1 tosupport the magnet 150 within the stator component 145 supported by thebearing-housing structure 130. The impeller 180 is coupled to the rotorcap 160 so it extends above or around the motor components. In a furtheralternative arrangement, as shown in FIG. 100 , the motor may include anaxial gap motor wherein the stator component 145 (including stator andwindings), magnet 150 and rotor cap 160 have a stacked or pancakeconfiguration. However, it is to be understood that the motor may haveany arrangement suitable to drive rotation using an electromagneticinteraction.

Motor Assembly

FIGS. 3-5 illustrate the assembled motor 140 within the blower 100. Themotor is structured such that the bearing-housing structure 130 providesa support for the other components of the motor as well as providing thebearing function to facilitate rotation of the rotor assembly. In theillustrated example, one end portion 170(1) of the rotor 170 (e.g.,metal or plastic) is rotatably supported within the bearing shaft 136 ofthe bearing-housing structure 130 and the other end portion 170(2) ofthe rotor 170 is inserted freely into the rotor cap 160, i.e., rotor notfastened to motor. The rotor cap 160 includes an opening 162 to receivethe rotor 170 (e.g., see FIGS. 12 and 13 ). However, rotor retentiondesigns may be incorporated into certain examples to retain the rotorand/or rotor assembly within the motor especially when the motor is notin use as described in more detail below.

The hub 185 of the impeller 180 is provided along the exterior surface163 of the rotor cap 160, and the magnet 150 is provided along theinterior surface 165 of the rotor cap 160, for example by frictionalengagement or by the use of an adhesive. The interior surface 165 mayprovide a recess or groove 165(1) to receive the magnet 150 (e.g., seeFIG. 13 ).

In an alternative example, as shown in FIG. 108 , the rotor cap and theimpeller may be integrally formed as a one-piece structure, e.g., rotorcap and impeller molded in one piece from a plastic material, e.g.,Lexan®, polycarbonate (e.g., glass reinforced polycarbonate), Polyetherether ketone (PEEK) or other suitable materials. As illustrated, theone-piece structure includes a rotor cap portion 360 and an impellerportion 380. A metal sleeve 351 and a magnet 350 are provided along theinterior surface of the rotor cap portion 360. The sleeve 351 provides amagnetic return or flux path between the poles of the magnet 350.Another example of a one-piece rotor cap and impeller is described inU.S. Pat. No. 7,804,213, which is incorporated herein by reference inits entirety.

In a further alternative example (not shown), the impeller may beovermolded onto the rotor cap. A diamond neural or other surface finishmay be provided on the surface of the rotor cap to facilitate thefixturing or attachment of the overmolded impeller.

The magnet 150 is coupled to the interior surface of the rotor cap 160and is located to facilitate magnetic interaction with the statorassembly to drive the motor. The magnet may be made from any permanentmagnet material such as a bonded NdFeB ring, a ferrite material,samarium cobalt or other such magnetic material. In certain examples,the magnet may be centered on the stator assembly. In another example,the magnet 150 may be off-set from the stator assembly to magneticallypreload a thrust bearing portion of the bearing-housing structure 130.In this arrangement, a pre-load spring may be not required for thebearing. Off-setting the magnet 150 may also assist with retaining therotor assembly within the motor.

The stator assembly 145 is coupled to the bearing-housing structure 130to retain the stator assembly 145 in position. The stator assembly 145may be coupled to the bearing-housing structure 130 by a snap-fit,over-molding, adhesively bonded, or other fastening means. The statorassembly or stator component 145 is provided along the exterior surface136(3) of the bearing shaft 136 of the bearing-housing structure 130. Inuse, the stator assembly 145 acts on the magnet 150 which causesspinning movement of the rotor cap 160 and hence the impeller 180. Thisarrangement at least partially “nests” the motor (stator assembly, fixedmagnet and rotor cap) within the impeller to reduce the size of theblower. In an example, components of the motor are at least partiallywithin a common (horizontal) plane.

As shown in FIGS. 17 and 18 , the stator assembly 145 includes a statorcore 146 having a plurality of stator teeth 147, e.g., six stator teeth,on which stator coils or windings are wound. In the illustrated example,the stator core 146 includes a plurality of laminations, e.g. 2-100laminations or more, that are stacked on top of one another. Thelaminations may be affixed to one another using adhesives or othertechniques. The number of laminations may depend upon the powerrequirements of the motor. Alternatively, the stator core may have adifferent arrangement such as a solid member rather than a stack oflaminations.

The stator assembly 145 may also include a pair of slotliners, e.g.,first and second slotliners 148-1 and 148-2 as shown in FIGS. 17 and 18, structured to insulate the stator core 146 from the stator coils orwindings. First and second slotliners 148-1 and 148-2 may be provided toopposite sides of the stator core 146 prior to winding the stator coilsonto the stator core. The thickness of the slotliners may be controlledto facilitate the packing of more stator coil or winding into thestator. However, in an alternative arrangement, the stator core may becoated with a material, for example, by powder coating the stator core.In certain examples, the slotliners may include those described in theapplicants pending U.S. patent application publication numberUS-2009-0324435, published Dec. 31, 2009, and entitled “Insulator forStator Assembly of Brushless DC Motor,” which is incorporated herein byreference in its entirety.

The stator coils or winding comprise magnet wire or motor wire such ascopper wire, for example. In an example, the stator assembly maycomprise three motor wires for a 3 phase motor, e.g., 2 coils per phase,45 turns per coil, however other coil arrangements are possible. Thedifferent wires for each phase may each be identified by using adifferent color for each of the motor wires. The motor wires may bedirectly interfaced to a PCB coupled to the blower for ease of assembly.Further, the center tap and lead wires may be bonded to the housing tominimize loose motor wire entering into the air path. In an examplearrangement, the motor wires may be routed through the stator vanes to aPCB assembly or driver as described below. The motor wires may be routedtogether and twisted for ease of wire egress. However, the motor wiresmay be routed out separately. The motor wire is wound onto the statorcore.

Rotor Retention

In certain examples, one or more rotor retention designs or structuresmay be included to assist in retaining the rotor and/or rotor assemblywithin the motor especially when the motor is not in use. For example,one or more over-top rotor retention arms may be attached to the topcover and over the rotor assembly to prevent vertical movement of therotor assembly. FIG. 19 shows an example an over-top retention arm 202having one end 202(1) attached to the top cover 120, e.g., by afastener, and the opposite end 202(2) positioned over the rotor assembly(i.e., rotor cap 160, magnet 150, and rotor 170).

In another rotor retention example, the bearing-housing structure 130may be coupled or interlocked to a mating feature in the rotor cap 160.For example, as shown in FIGS. 20 and 21 , the bearing-housing structure130 may comprise a slot or groove 131 on the thrust bearing surface136(2) configured to receive a lip or ridge 161 present on the matingfeature of the rotor cap 160. The lip or ridge 161 on the rotor cap 160may snap-fit into the slot or groove 131 on the thrust bearing surface136(2). The mating feature may be incorporated at the lower surfacesurrounding the aperture 162 of the rotor cap 160. The snap-fit designmay also include radii, fillet and/or chamfers to assist with theconnection. The ridge or lip may be provided around the entirecircumference of the mating feature of the rotor cap 160 or may belimited to a plurality of discrete snaps, beads, or protrusions atlocations around the mating surface, such as 2-10 snaps or protrusionsor more.

FIGS. 22-27 show alternative examples of mating features to couple therotor cap to the bearing housing structure. FIG. 22 is similar to thearrangement of FIGS. 20 and 21 in which the rotor cap 160 includes a lipor ridge 161 to engage within a slot or groove 131 provided to thebearing-housing structure 130. In FIG. 23 , the rotor cap includes abead 161-1 adapted to engage within a groove 131-1 provided to thebearing-housing structure 130. In FIGS. 22 and 23 , the mating featuresengage along an inwardly facing surface of the bearing-housingstructure, i.e., surface facing the rotor. FIGS. 24 and 25 showarrangements in which the mating features engage along an outwardlyfacing surface of the bearing-housing structure, i.e., surface facingaway from the rotor. For example, FIG. 24 shows a rotor cap including abead 161-2 adapted to engage within a groove 131-2 provided to thebearing-housing structure 130, and FIG. 25 shows a rotor cap including arecess 161-3 adapted to engage with a bead 131-3 provided to thebearing-housing structure 130. FIGS. 26 and 27 show an arrangement inwhich the rotor cap 160 includes a plurality of discrete beads 161-4(e.g., 4 beads) adapted to engage within a groove 131-4 provided to thebearing-housing structure 130.

FIG. 28 shows another rotor retention example in which a lower flange,ridge or projection 171 is coupled to the bottom of the rotor or shaft170 (e.g., constructed of stainless steel and press-fit to rotor) thatis positioned underneath the bearing-housing structure 130. The lowerflange 171 prevents the rotor 170 from lifting vertically out of themotor assembly 140. The lower flange may also provide an additional oralternative rotating surface for the rotor 170.

In certain examples including a pre-swirl cover as shown in FIG. 29 , asdescribed in more detail below, the pre-swirl cover 205 may furtherinclude an axial shock bumper or stop 205-1 to prevent the rotorassembly (i.e., rotor cap 160, magnet 150, and rotor 170) or rotor 170from separating from the motor assembly in the case of a shock. Forexample, the bumper or stop 205-1 may prevent the rotor assembly fromlifting off the bearing-housing structure's thrust bearing surface ifthe blower is dropped or bumped, especially when not in use. The bumperor stop is arranged above the rotor 170 in a manner that prevents therotor and/or rotor assembly from lifting up and out of the motorassembly. The bumper or stop may include a ball, such as a steel ball, aflat surface or any other means that would maintain the rotor and rotorassembly in the correct position within the motor.

In another rotor retention example, as shown in FIGS. 30 to 32 ,complimentary screw threads 161-5, 131-5 may be incorporated on therotor cap 160 and the bearing thrust surface 136(2) of thebearing-housing structure 130, respectively. In such a design, the rotorassembly (i.e., rotor cap 160, magnet 150, and rotor 170) must bescrewed over the screw thread and fully engaged with the bearing thrustsurface 136(2) of the bearing-housing structure 130 before the rotorassembly may freely rotate. The screw threads would be configured in thesame direction in which the rotor rotated to prevent the release oruncoupling of the rotor assembly in use. The rotor assembly may beremoved by rotating or unscrewing the rotor assembly in the oppositedirection to normal rotation. FIG. 30 shows the rotor assembly andbearing-housing structure before engagement, FIG. 31 shows the rotorassembly and bearing-housing structure partially engaged, and FIG. 32shows the rotor assembly and bearing-housing structure fully engaged.

Blower Housing

The top cover 122 provides an inlet 123 at one end of the blower and thebottom cover 124 provides an outlet 125 at the other end of the blower.The blower is operable to draw a supply of gas into the housing throughthe inlet and provide a pressurized flow of gas at the outlet. Theblower has axial symmetry with both the inlet and outlet aligned with anaxis of the blower. In use, gas enters the blower axially at one end andleaves the blower axially at the other end.

In another example, the blower may include an axial aligned inlet and anoutlet that is tangential to the inlet.

The top and bottom covers (e.g., constructed of a plastic material) maybe attached to one another by fasteners, e.g., plurality of openings 126provided along flange-like perimeter of covers 122, 124 to allowfasteners to extend therethrough. In addition, the top and bottom coversmay provide a joint 128 (e.g., tongue and groove arrangement as shown inFIGS. 3 and 4 ) along its perimeter to facilitate alignment andconnection. However, it should be appreciated that the covers may beattached to one another in other suitable manners, e.g., ultrasonicweld.

As shown in FIGS. 8 and 9 , the bottom cover 124 includes a plurality ofstator vanes or de-swirling vanes 129, e.g., between about 2 and 50stator vanes or about 15-30 or about 5-15, to direct airflow towards theoutlet 125, e.g., also referred to as flow straighteners. In theillustrated example, the bottom cover has 6 stator vanes. Each vane issubstantially identical and has a generally spiral shape. In theillustrated example, the leading edge of each vane extends generallytangential to flow so as to collect air exiting the impeller and directit from a generally tangential direction to a generally radialdirection. In the illustrated example, the stator vanes support thebearing-housing structure 130 within the cover.

In certain examples, one or more of the de-swirling vanes 129 may bestructured as dual vanes that provide a passage to allow for the motorwires to be routed through the vanes and out to the PCB or driver. Forexample, FIGS. 33 to 35 show exemplary deswirling vanes 129 eachincluding spaced apart side walls or dual vanes 129-1, 129-2 thatprovide a space 129-3 therebetween. A cylindrical guide 129-4 isprovided within the space that allows motor wires 203 (e.g., see FIG. 35) to be routed through the vane. FIG. 33 shows an example of a dual vanearrangement in relation to a single vane arrangement. FIG. 8 shows anexample in which three of the deswirling vanes 129 include a dual vaneconfiguration that provide passage for motor wires. In another example,only one or two of the deswirling vanes may include a dual vanestructure for routing all motor wires.

FIGS. 101 and 102 illustrate another example of a de-swirling vanearrangement for the bottom cover. In this example, the vanes includedifferent thicknesses. For example, one of the vanes 129.1 is relativelythick while the remaining vanes 129.2 (e.g., remaining 5 vanes) arerelatively thin with respect to the vane 129.1. However, it should beappreciated that the thickness arrangement may have other suitablearrangements, e.g., same number of thick/thin vanes, more thin thanthick vanes, more thick than thin vanes, all vanes have differentthicknesses, etc.

In certain examples, as shown in FIGS. 28, 29 and 36 to 38 , the blowermay also include a plurality of pre-swirl inlet vanes 206 located abovethe inlet 123 and above or on the top cover 120. The plurality of inletvanes 206, e.g., between about 2 and 50 inlet vanes or about 15-30 orabout 5-15, such as 5, 6, 7, 8, 9, 10, or 11 vanes, are structured todirect airflow towards the inlet 123. Each inlet vane 206 issubstantially identical and has a curved profile (e.g., see FIG. 37 ) todirect the airflow towards the inlet 123. The inlet vanes are structuredto pre-swirl the incoming air to facilitate a reduction in shock lossesat the leading edge of the impeller blades. The inlet vanes may alsoassist in reducing the radiated noise from the inlet 123. The inletvanes may further assist in increasing the efficiency of the blower. Incertain examples, the pre-swirl vanes are coupled to the outer surfaceof the top cover 120. The pre-swirl vanes may be integrally molded intothe top cover 120 or attached via gluing, ultrasonic welding, snap fit,adhesive or some other fastening means. FIGS. 103 and 104 show anexample of pre-swirl vanes 206 integrally molded or otherwise attachedto the top cover 120.

As shown in FIGS. 28, 29, and 36 to 38 , the pre-swirl vanes 206 arecovered by a pre-swirl cover 205 structured to cover the pre-swirl vanesand form a plurality channels to direct the air flow towards the inlet123. The pre-swirl cover is coupled to the top edge of the pre-swirlvanes on the top cover 120, e.g., by heat staking, ultrasonic welding,gluing, adhesive or other such fastening means. FIGS. 105 to 107 showthe top cover 120 and vanes 206 of FIGS. 103 and 104 with a pre-swirlcover 205 coupled to the vanes. The pre-swirl cover may be made from aplastic material, metal, aluminum or other suitable materials, forexample the pre-swirl cover may be molded from a plastic material orformed by metal injection molding. The pre-swirl cover may be moldedfrom or over-molded with a low durometer material such as a silicone orurethane, to provide a dampening function. In an alternative example,the pre-swirl vanes 206 may be integrally molded with the pre-swirlcover 205 and the top cover 120 is coupled to the bottom edge of thepre-swirl vanes 206. FIG. 38 also shows a bumper or stop 205-1 on thepre-swirl cover 205, as described above in relation to FIG. 29 .

Inlet Cap

In an example, an inlet cap may be provided to the inlet, e.g., toreduce noise. The inlet cap may be integrally formed in one-piece withthe top cover. Alternatively, the inlet cap may be formed separatelyfrom the top cover and attached or otherwise provided to the inlet ofthe top cover. In an example, the inlet cap may be structured to supportor otherwise retain a filter to filter the incoming air.

For example, FIGS. 116 to 119 show a blower 300 including an inlet cap310 provided to the inlet 323 of the top cover 322 according to anexample of the present technology. The remaining components of theblower are similar to that shown in FIGS. 109-110 , which is describedin greater detail below, e.g., blower includes a bearing-housingstructure 330 structured to support a bearing cartridge 390 adapted torotatably support the rotor 370.

As illustrated, the inlet cap 310 includes a generally disk-shaped innerportion 312, a generally ring-shaped outer portion 314, and radiallyextending spokes or connectors 316 that interconnect the inner and outerportions 312, 314. The outer portion 314 of the inlet cap 310 engagesthe annular side wall 322(1) of the top cover 322 defining the inlet 323to support the inlet cap 310 at the inlet 323. The outer portion 314overhangs the side wall 322(1) to secure the inlet cap in position andalign the inlet cap with the axis of the inlet. In an example, the inletcap may engage the side wall with a press or friction fit, however, itshould be appreciated that the inlet cap may be secured to the side wallin other suitable manners, e.g., adhesive, mechanical interlock (e.g.,snap-fit), ultrasonic welding, etc.

In use, the inner portion 312 is positioned to occlude or block acentral portion of the inlet 323 and a supply of gas is drawn into thehousing through the annular gaps 315 defined between the outer edge ofthe inner portion 312 and the inner edge of the outer portion 314. In anexample, the cross-sectional area provided by the gaps 315 (i.e., inletarea) is greater than about 150 mm², e.g., about 150-300 mm², 175-225mm², 200-250 mm², 250-300 mm². Such arrangement reduces noise, e.g., byreducing radiated noise from the inlet by reducing the effective inletarea, by reducing the Helmholtz resonance frequency.

In the illustrated example, the inner portion 312 includes a diameterthat is less than a diameter of the rotor cap 360, e.g., diameter ofinner portion 312 less than about 20 mm, e.g., 18 mm. However, it shouldbe appreciated that in other examples the inner portion may include adiameter that is similar to or greater than a diameter of the rotor cap.

In an example, as shown in FIG. 124 , the clearance A between the rotorcap 360 and inner portion 312 of the inlet cap 310 is substantiallysimilar to the clearance A between the impeller 380 and top cover 322,e.g., clearance A greater than 0.1 mm, e.g., greater than about 0.1 mmto 1.0 mm, such as between 0.3 mm and 0.5 mm, or between 0.35 mm to 0.4mm, or greater than 0.381 mm, such as greater than about 0.381 mm to 1.0mm. Also, in an example, as shown in FIG. 124 , the thickness B of theinner portion 312 of the inlet cap 310 is substantially similar to thethickness B of the top cover 322.

In the illustrated example, the inlet cap includes three spokes orconnectors 316, however it should be appreciated that more or lessspokes may be provided, e.g., 2, 4, 5, 6 or more spokes. Also, it shouldbe appreciated that the spokes or connectors may include otherconfigurations and may be arranged in other suitable manners tointerconnect the inner and outer portions 312, 314.

For example, FIGS. 120 to 123 show inlet caps according to alternativeexamples of the present technology. In FIG. 120 , the inlet cap 410includes a larger number of radially extending connectors 416, e.g., 17connectors, than the inlet cap 310 described above interconnecting theinner and outer portions 412, 414. However, it should be appreciatedthat more or less connectors are possible.

In FIG. 121 , the inlet cap 510 includes a plurality of connectors 516,e.g., 10 connectors, that extend tangentially from the inner portion 512to interconnect the inner portion 512 with the outer portion 514. Also,the connectors may be skewed or angled towards horizontal, e.g., toenhance noise reduction.

In FIG. 122 , the connectors 616, e.g., 7 connectors, between the innerand outer portions 612, 614 of the inlet cap 610 include a generallycurved configuration.

In FIG. 123 , the connectors 716, e.g., 15 connectors, between the innerand outer portions 712, 714 of the inlet cap 710 are in the form ofcylinders.

It should be appreciated that the number of connectors 416, 516, 616,716 may be varied and the above numbers are only exemplary, thus more orless connectors 416, 516, 616, 716 may be utilized, such as 2, 3, 4, 5,6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18 or more connectors.

Bearing-Housing Structure

In an example, the blower does not require or use ball bearings torotatably support the rotor. Rather, the bearing-housing structure 130(rotatably supports the rotor 170 along with the rotor cap 160 andretains the stator assembly 145 of the motor 140. The bearing-housingstructure 130 may also comprise a shielding disk between the impellerblades and the stator vanes. The bearing-housing structure 130 isconstructed of a lubricous material such as sintered bronze, anengineered plastic material, e.g., a polyamide-imide resin such as aTorlon™, and/or other very low friction materials or a combination ofmaterials including a lubricous material or a material having a very lowcoefficient of friction. For example, a first material such as analuminum, steel, brass, bronze or other metal or plastic may be coatedwith a lubricous material or material having a very low coefficient offriction such as a ceramic based or a nickel based coating material. Incertain examples, the coating may be applied only to the critical wearsurfaces of the bearing-housing such as the shaft receiving surface.Alternatively or additionally, the shaft may be coated with suchmaterials to reduce friction.

As shown in FIGS. 10 and 11 , the bearing-housing structure 130 includesa base 132, an annular flange or disk 134 extending from the base, and arotor or bearing shaft 136 that rotatably supports the rotor 170. Thebearing shaft 136 includes a radial or sleeve bearing portion 136(1) anda thrust bearing portion 136(2). The thrust bearing portion 136(2) is atthe top surface of the bearing-housing structure 130 surrounding therotor 170 and adjacent the rotor cap 160. The thrust bearing portion136(2) provides a thrust surface to allow the rotor cap to rotate. Theradial bearing portion 136(1) is configured as a sleeve bearing alongthe surface of the rotor and provides a radial surface along the rotorto facilitate rotation of the rotor 170. The rotor may be polished toprovide a desired surface finish at the rotor cap thrust surface. Thesurface finish may be attained using one or more techniques includinggrinding, diamond burnishing, lapping and polishing and/or chemicaltumbling or any other surface generation techniques. The surface finishmay be provided with a micro finish of between 3 micro-inches root meansquare (RMS) to 40 micro-inches RMS, such as 3 micro-inches RMS to 32micro-inches RMS, such as 8 micro-inches RMS to 16 micro-inches RMS. Incertain examples, the surface finish may not be super highly polished asthis may create some friction. Alternatively, the surfaces may be coatedwith a lubricous or very low coefficient of friction material asdescribed above rather than being polished. The bearing shaft provides asingle bearing incorporating both radial and thrust bearing propertieswhich assists in reducing the height of the blower. A thrust load may beprovided to the thrust bearing portion 136(2) of the bearing-housingstructure 130. The thrust load is provided by the rotor cap 160 on a topsurface or thrust surface 136(2) of the bearing shaft in use. As thereis only a single bearing, the motor only requires balancing in one planeand not two planes.

The disk 134 of the bearing-housing structure provides support to therotor. The outer edge 134(1) of the disk 134 substantially aligns withor extends radially beyond the outer edge of the impeller 180 to preventa line of sight between the tips of the impeller blades and thede-swirling vanes 129. The outer edge 134(1) of the disk 134 provides ashielding function to prevent blade pass tonal noise from beinggenerated from the de-swirling vanes of the bottom cover 124 when theimpeller spins in use. The disk 134 provides a narrow annular gap 135,e.g., about 0.75 mm, between its outer edge and the side wall of thecover 120, which is sufficient to allow enough gas to flow towards theoutlet without significant loss in pressure and motor efficiency. Incertain examples, the gap may be between 0.4 mm and 100 mm, e.g.,between 0.4 mm and 2 mm, such as 0.5 mm, 0.75 mm, 1 mm or 1.5 mm. Also,the disk may include one or more openings for guiding the motor wire tooutside of the air path, e.g., see FIGS. 28, 29, and 35 showing motorwire 203 routed through opening 144 in disk 134.

In certain examples, the bearing-housing structure 130 may have a splitconfiguration that is assembled from a separate disk component 134 and aseparate bearing component 136, e.g., also including the base 132. Inthis split configuration, the disk component 134 and the bearingcomponent 132, 136 may be constructed of different materials. Forexample, the bearing component 132, 136 may be constructed of alubricous material as described above and the disk component 134 may beconstructed of a plastic, polycarbonate or similar materials. Theseparate disk component 134 may be coupled to the bearing component 132,136 using a range of different coupling systems. The coupling systembetween the disk component 134 and the bearing component 132, 136 mayinclude one or more of the following systems: over molding one componentonto the other component, e.g., over molding the disk component 134 ontothe base 132 or vice versa; using a snap-fit or clip arrangement; usingan interference fit; using a screw or bayonet connection; using anelastomeric component coupled between the disk component 134 and thebase 132 such that no direct fastening of the disk component to the base132 is required, the elastomeric component, e.g., TPE, may be overmolded onto the end of the disk component, or the base 32 or both; orany other coupling system. One or more elastomeric or complaintcomponents, such as TPE over molds or o-rings, may be included in any ofthe above coupling systems between the disk component 134 and the base132 to reduce the transmission of vibration.

For example, FIG. 39 shows an example of a separate disk component 134coupled to a separate, cylindrical bearing component 136, e.g.,overmolded with one another. In FIG. 40 , the base 132 of the separatebearing component 136 is interlocked within a groove provided to theseparate disk component 134, e.g., to enhance connection betweencomponents. In FIGS. 41 and 42 , an o-ring 138 is provided between theseparate disk component 134 and the separate bearing component 132, 136,e.g., to minimize vibration transmission. Also, one or more o-rings 139may be provided between the bearing component 132, 136 and the bottomcover 124 to minimize vibration transmission. FIG. 45 shows a separatebearing component 132, 136 with an elastomer 137 overmolded along theedge of the base 132. The separate disk component 134 (e.g., constructedof plastic) may be ultrasonically welded or heat staked to vanes 129 ofthe bottom cover 124.

In such split configuration examples, the plurality of stator vanes orde-swirling vanes 129 positioned below the disk component 134 may beeither located on the disk component or on the bottom cover 124 asdescribed above or both, such that some of the stator vanes 129 arelocated on the disk component 134 and some of the stator vanes 129 arelocated on the bottom cover 124 to provide the complete set of statorvanes 129. The stator vanes 129 may be integrally formed or molded withthe disk component 134 and/or the bottom cover 124. For example, FIG. 43shows a separate bearing component 132, 136 overmolded with a separatedisk component 134, the disk component 134 including stator vanes 129integrally formed or molded therewith. The bottom cover 124 supports theend portion of the vanes, e.g., end portion of vanes molded into thebottom cover.

Such split configurations allow motor wires or stator wires to be routedout of the blower assembly between the disk 134 and base 132, e.g., seeFIG. 43 showing motor wires 203 routed between disk component 134 andbearing component 132, 136 and through an exit in the bottom cover 124.The motor wires may be routed to an exit within the bottom cover andattached to a PCB Assembly or driver, e.g., see FIG. 44 showing motorwires 203 routed through bottom cover 124 and to the PCB assembly ordriver 207. The motor wires may also be routed through at least some ofthe stator vanes 129 as described above. In certain examples, the PCBassembly or driver may be mounted to the bottom cover outside the airpath, e.g., see FIG. 44 in which PCB assembly or driver 207 mounted toexterior portion of the bottom cover 124 outside the air path.

In other certain examples, the disk 134 may be a separate component thatacts as a shield as described in U.S. Pat. No. 7,866,944 entitled“Compact low noise efficient blower for CPAP devices,” which isincorporated herein by reference in its entirety.

The bearing-housing structure may be coupled to the bottom cover 124 tofacilitate assembly of the blower. The bearing-housing structure 130 maybe coupled to the bottom cover 124 at 2 or more positions, such as 3-6positions or more. At least some of the stator vanes 129 on the bottomcover may be coupled to the disk 134 of the bearing-housing structure130. However, if the stator vanes are located on the disk 134, at leastsome of the stator vanes 129 may be coupled to the bottom cover. Thestator vanes 129 may be coupled to the disk 134 and/or the bottom coverby any means including one or more of the methods described below orcombinations thereof or any other coupling method.

In certain examples, at least some of the stator vanes 129 may beadhesively coupled to the disk 134 and/or bottom cover 124, such asusing a glue or double side tape. For example, FIG. 46 shows the disk134 coupled to stator vanes 129 by double side tape 208. FIG. 47 showsan example, in which the stator vanes 129 of the bottom cover 124 areovermolded TPE or hard plastic which may be adhesively bonded to thedisk 134. In other examples, the stator vanes 129 may be coupled to thedisk 134 and/or bottom cover 124 by heat staking or ultrasonic welding.For example, FIG. 29 shows the bearing-housing structure 130 heat-stakedonto the bottom cover 124. In such example, the vanes 129 are overmoldedwith an elastomer 129-5, e.g., to minimize vibrations. In otherexamples, the stator vanes 129 may be coupled to the disk 134 and/orbottom cover 124 using a press-fit arrangement wherein protrusions on anedge of the stator vanes are received within complementary apertures inthe disk 134 or bottom cover 124 or vice versa in that the protrusionsare on the disk 134 and/or bottom cover 124 and the complementaryapertures are on the stator vanes 129. Further examples may utilize asnap-fit, interference fit, clip or boss arrangement to couple thestator vanes 129 to the disk 134 and/or bottom cover 124.

The top or bottom edges of the stator vanes 129 may include anelastomeric material to minimize vibration transmission from the bearinghousing structure 134 to the bottom cover 124. The elastomeric materialmay be over-molded, adhesively attached, or inserted on to the edges ofthe stator vanes 129. The elastomeric material, such as an o-ring, maybe retained between the coupled stator vanes 129 and the disk 134 and/orbottom cover due to coupling means. For example, FIG. 48 illustrates ano-ring or TPE overmold 139 placed between the bearing housing structure130 and the bottom cover 124 for vibration isolation. The bearinghousing structure may be heat staked onto the bottom cover to retain theo-ring in position.

In certain examples, the bearing-housing structure 130 may be coupledadditionally or alternatively directly to the bottom cover 124, i.e.,not via the stator vanes 129. In an example as shown in FIGS. 49 and 50, the bearing-housing structure 130 may comprise a boss 130-1 that isengaged with a fastener 209 at the bottom cover 124. As best shown inFIGS. 50 to 52 , the fastener 209 may include a plurality of teeth-likeprotrusions 209-1 that grip or bite into and retain the boss 130-1. Theteeth-like protrusions may be angled to allow ease of insertion of theboss in one direction but prevent or hinder release of the boss in theopposing direction. The fastener may be a separate component that isinserted through the bottom cover to couple the bottom cover 124 andhousing-bearing structure 130. Alternatively, the boss may be located onthe bottom cover 124 and the fastener on the bearing-housing structure130.

In another arrangement, as shown in FIG. 53 , the boss 130-1 may beintegrated with the bearing housing structure 130 and configured topress-fit into the bottom cover 124 until at least a portion of some ofthe stator vanes 129 contact the disk 134 of the bearing housingstructure 130. A fastener 210, such as a Tinnerman clip, pal nut, speednut, push nut or other fastener, may secure the bearing housingstructure to the bottom cover. FIG. 54 shows another example of thebearing housing structure 130 secured to the bottom cover 124 by afastener 210, e.g., Tinnerman clip. In this example, the bearing bore orthrough hole 133 in the bearing housing structure in the area of thebottom cover (i.e., lower portion of bore 133) may be slightly larger indiameter as compared to area of the bearing sleeve or rotor support(i.e., upper portion of bore 133 that supports rotor 170) to minimizecompressive shrink due to press fit of fastener, e.g., Tinnerman clip.

In other certain examples, the boss of the bearing-housing structure 130may comprise a protrusion including one or more lips that are configuredto engage with a fastener at the bottom cover 124. The fastener may haveone or more mating grooves adapted to receive the lip(s) in a snap fitarrangement. Alternatively, the protrusion may be located on the bottomcover 124 and the fastener on the bearing-housing structure 130. Otherfasteners that may be used include Tinnerman clips, pal nuts, speednuts, push nuts and other such fasteners.

In other examples, the base 132 of the bearing-housing structure 130 maybe directly coupled to the bottom cover 124 via a snap feature thatsnaps into a groove. The snap feature may be located on the bottom cover124 and the groove on the bearing-housing structure 130 or vice versa.

For example, FIG. 55 shows a bottom cover 124 including a snap feature211 structured to snap into a groove provided on the bearing housingstructure 130 to attach the bottom cover the bearing housing structure.FIGS. 56 to 65 show alternative examples of snap features 211 forattaching the bottom cover 124 to the bearing housing structure 130.

In certain examples, as shown in FIG. 66 , the bottom cover 124 may becoupled to the bearing-housing structure 130 using a screw arrangement.A central screw 212 may be inserted via the outlet 125 through a portionof the bottom cover 124 and into a threaded anchor 213 provided to thebearing-housing structure 130 (e.g., anchor integrally molded or bored).The screw 212 may be inserted into an anchor portion 124-1 of the bottomcover 124 which further comprises at least one arm 124-2 that extendsupwards towards the disk 134 of the bearing-housing structure 130 toprovide support. The at least one arm 124-2 may be configured to couplewith the disk 134, e.g., interlocking engagement. This may facilitatedampening the bottom cover by clamping. Optionally, the screw may besealed over after assembly to prevent the screw from falling out orbeing removed or tampered with. The screw may seal the bottom of thebearing spindle and assist in preventing air flow therethrough and anybearing grease or lubricant from drying out. Bearing grease or lubricantmay be added to the bearing spindle prior to installing the screw. FIG.67 shows another example of the bottom cover 124 coupled to thebearing-housing structure 130 by a central screw 212.

In certain examples, the screw arrangement may be integrated into thebottom cover 124 and/or the bearing-housing structure 130. For example,as shown in FIG. 68 , the bearing-housing structure 130 may beconfigured to comprise a threaded screw portion 212-1 (e.g., male screwportion) at the end of the bearing shaft 136 that is received within acorresponding threaded screw receiving portion 212-2 (e.g., female screwportion) in the bottom cover 124. Alternatively, the male screw portionmay be located on the bottom cover 124 and the female screw portion onthe bearing-housing structure 130. The screw portions allow thebearing-housing structure and the bottom cover to be screwed together.

Bearing grease or lubricant is used to assist in stabilizing the rotorassembly in the bearing-housing structure. Thus, means of retaining thelubricant may be incorporated within the motor assembly. As shown inFIG. 69 , a lubricant reservoir 215 may be built into the bearing shaft136 of the bearing-housing structure 130 that is designed to supply thelubricant to the bearing thrust surface 136(2). A supply of lubricantmay be fed to the reservoir 215 via an aperture 216 through thebearing-housing structure. The bearing shaft 136 may include one or morerecessed channels 217 (e.g., see FIG. 70 ), e.g., 3-10 channels, 4-8channels, 4-6 channels, 4, 5, or 6 channels, etc., along the bearingthrust surface 136(2) to focus pressure points at the top and/or bottomof the bearing shaft 136. The recessed channel(s) assist in retainingthe lubricant at the rotating surface.

FIGS. 71 to 74 illustrate an example of a bearing-housing structure 130including a lubricant reservoir 215 within the bearing shaft 136. In anexample, as shown in FIG. 73 , the lubricant reservoir 215 may besubstantially centrally located within the bearing shaft 136, e.g., d1and d2 about 1.5 to 3.0 mm, e.g., about 2.25 mm. In an example, as shownin FIG. 73 , the depth d3 of the reservoir is about 0.05 to 0.1 mm,e.g., about 0.08 mm or about 0.003 inches.

FIGS. 75 to 79 illustrate an example of a bearing-housing structure 130including one or more recessed channels 217 (also referred to as lands)along the bearing thrust surface 136(2) of the bearing shaft 136 toassist in retaining lubricant at the rotating surface. In an example, asshown in FIGS. 77 and 78 , the length d1 of each channel is about 0.5 to1.0 mm, e.g., 0.8 mm, the width d2 of each channel is about 0.2 to 0.6mm, e.g., 0.4 mm, the radius of curvature d3 is about 0.2 mm, the depthd4 is about 0.01 to 0.05 mm, e.g., 0.025 mm (about 0.001 inches), andthe radius of curvature d5 is about 0.0155 inches. However, it should beappreciated that other suitable dimensions for the channels arepossible. For example, the dimensions may be selected to adjust thehydrodynamic pressure provided by the channels, e.g., FIG. 80 showschannels 217 each having a width of about 0.016 inches and FIG. 81 showschannels 217 each having a smaller width of about 0.011 inches.

FIGS. 82 and 83 schematically illustrate the hydrodynamic pressureconcentration (outlined in dashed lines) created by the channels 217between the bearing shaft 136 and the rotor cap 160 in use.

FIGS. 84 to 89 illustrate an example of a bearing-housing structure 130including an annular recessed channel 217 along the bearing thrustsurface 136(2) of the bearing shaft 136 to assist in retaining lubricantat the rotating surface. In an example, as shown in FIG. 88 , the depthd1 of the channel is about 0.01 to 0.04 mm, e.g., 0.025 mm, the radiusof curvature d2 is about 0.3 to 0.5 mm, e.g., about 0.4 mm, d3 is about1.5 to 2 mm, e.g., about 1.9 mm, and d4 is about 0.25 to 0.5 mm, e.g.,about 0.4 mm.

Preferably, the bearing shaft or sleeve has a trilobe configurationrather than a circular configuration. For example, FIG. 90 shows anexample of a bearing shaft with a trilobe configuration with respect tothe rotor 170 in use. Each “lobe” increases the fluid dynamic orhydrodynamic pressure. In an example, the depth d1 of each lobe is about0.0001 to 0.0005 inches.

In certain examples, as shown in FIG. 91 , a retaining ring 218, such asan acorn shaped grooveless retaining ring, may be coupled to the bottomof the bearing shaft 136 to assist in retaining the lubricant around thebearing-housing structure 130.

In certain examples, as shown in FIG. 92 , the bearing-housing structure130 may be closed at one end, such as the lower end 130.1, of the radialbearing portion 136(1) to retain the lubricant within the bearing shaft.

The grease or lubricant may include a Kyoto Ushi Multem or other suchlubricants. Alternatively, the bearing may be a dry bearing, i.e., thebearing-housing and/or rotating components are formed at least in partor coated with a low friction material such as a low coefficient offriction material, e.g., a ceramic based coating, a nickel basedcoating, Teflon™ or graphite, that provides lubricity and eliminates therequirement for a grease or lubricant.

Bearing Cartridge

In an alternative example, as shown in FIGS. 109-110 and 125-127 , thebearing shaft of the bearing-housing structure may be replaced with abearing cartridge 390 including bearings 394, 395 adapted to rotatablysupport the rotor 370.

As illustrated, the bearing cartridge 390 includes a tubular sleeve orcartridge 392, two spaced-apart bearings 394, 395 supported within thesleeve 392, and a spacer 396 (which may be optional) between thebearings to provide a preload (e.g., direction of preload shown byarrows a1 and a2 in FIG. 112 ). Each bearing 394, 395 includes an outerrace engaged with the interior surface of the sleeve 392 and an innerrace engaged with the rotor 370, e.g., bonded using an adhesive. FIG.112 is an isolated view of the bearing cartridge 390.

In this example, the bearing-housing structure 330 (e.g., injectionmolded of plastic material) includes a housing part providing a base 332and an annular flange or disk 334 extending from the base 332. The base332 provides a tube portion 333 that supports an end of the bearingcartridge 390, e.g., an exterior surface of the sleeve 392 of thebearing cartridge 390 is bonded in the tube portion 333, e.g., usingadhesive. Also, the stator component 345 is provided (e.g., bonded usingan adhesive) along the exterior surface of the sleeve 392.

In FIGS. 109 and 110 , the tube portion 333 is open ended and provides aflange 333(1) along the opening to provide a stop surface for supportingthe bearing cartridge 390 within the tube portion 333. In an example,such opening at the bottom of the tube portion may be capped or sealedoff. In an alternative example, as shown in FIG. 111 , the bottom of thetube portion 333 may be closed by an integral lower wall 333(2) toprovide the stop surface for supporting the bearing cartridge 390 withinthe tube portion 333.

In this example, as shown in 109, 126, and 127, stator vanes 329 of thebearing-housing structure 330 provide tabs 329(1) that are adapted toengage within respective openings 324(1) in the bottom cover 324 (e.g.,with a snap-fit, heatstake) to retain and align the bearing-housingstructure 330 with respect to the bottom cover 324. The top cover 322may be secured to the bottom cover 324, e.g., by adhesive or ultrasonicwelding or using other known methods.

As described above, the rotor cap 160 (supporting the magnet 150 andimpeller 180) is provided to the end portion 370(2) of the rotor 370. Inan example, the magnet may be centered on the stator assembly to removemagnetic preload or thrust from the rotor cap to the bearing cartridge.

In an example, the rotor cap 160 may be provided to the rotor 370 (e.g.,press-fit) in a first assembly operation, and then the rotor 370 (withthe rotor cap attached thereto) may be provided to the bearing cartridge390 in a second assembly operation. Such assembly may impart less damageto the bearings of the bearing cartridge.

In an alternative example, the bearing cartridge may include a singlebearing adapted to cooperate with another bearing supported in thehousing for rotatably supporting the rotor.

In another alternative example, an air bearing arrangement may beprovided to support the rotor.

Tangential Outlet

In an example, the blower may include an axial aligned inlet and anoutlet that is tangential to the inlet or tangential to the direction ofrotation of the impeller.

For example, FIGS. 128 to 131 show a blower 800 including a top cover822 providing an inlet 823 and a bottom cover 824 providing an outlet825 that is tangential to the inlet 823. Similar to examples describedabove, the blower includes a bearing-housing structure 830 structured tosupport a bearing cartridge 890 adapted to rotatably support the rotor870. The rotor cap 860 (supporting the magnet 850 and impeller 880) isprovided to an end portion of the rotor 870.

In this example, the bearing-housing structure 830 includes an annularside wall 835 that extends downwardly from an end portion of the disk834. The free end of the side wall 835 provides tabs 835(1) that areadapted to engage within respective openings in the bottom cover 824(e.g., with a snap-fit, heat stake, ultrasonic weld) to retain and alignthe bearing-housing structure 830 with respect to the bottom cover 824.

The side wall 835 along with the covers 822, 824 define a volute 837 fordirecting air towards the outlet 825. In this example, the volute 837expands in cross-sectional area towards the outlet to generate pressurevia static regain. The side wall 835 and bottom cover 824 also providean open space 839 out of the air flow path, e.g., for electroniccomponents such as a PCB or driver.

FIGS. 132-138 show another example of a blower including an outlet thatis tangential to the inlet. In this example, the blower 900 includes abearing-housing structure that is incorporated into or otherwiseprovided by the blower housing 920.

As illustrated, the blower housing 920 includes a top cover 922providing an inlet 923 and a bottom cover 924 that cooperates with thetop cover 922 to provide an outlet 925 that is tangential to the inlet923.

The bottom cover 924 is also structured to support the bearing cartridge990 and define the volute 937 for directing air towards the outlet 925.Specifically, the bottom cover 924 includes a base 932 providing a tubeportion 933 that supports the bearing cartridge 990 and an annularflange or disk 934 that curves upwardly and then extends radiallyoutwardly from the base 932. An annular side wall 935 extends downwardlyfrom an edge of the disk 934 to define the volute 937. The rotor cap 960(supporting the magnet 950 and impeller 980) is provided to an endportion of the rotor 970 rotatably supported by the bearing cartridge990.

In this example, the volute 937 expands in cross-sectional area towardsthe outlet to generate pressure via static regain, e.g., see FIG. 136 .In the illustrated example, the volute includes a generallysemi-circular cross-section configuration, e.g., see FIGS. 137 and 138 ,however other suitable volute shapes are possible.

FIGS. 139 to 142 show another example of a blower including an outletthat is tangential to the inlet. The blower 1000 includes housing 1020having a top cover 1022 and a bottom cover 1024. The top cover 1022provides the inlet 1023 and also provides the outlet 1025 that istangential to the inlet 1023. In this example, a chimney or inlet tubeportion 1027 is provided to the inlet 1023.

A bearing-housing structure or stationary component 1030 is provided tothe housing 1020 and is structured to support a bearing cartridge 1090and define a volute 1039 for directing air towards the outlet 1025.

The bearing-housing structure 1030 includes a tube portion 1033 thatsupports the bearing cartridge 1090, outwardly and upwardly extendingwall portions 1035, 1036 that defines a recess to receive motorcomponents, an annular flange or disk 1034, and a downwardly andoutwardly extending end portion 1037 extending from the disk.

The tube portion 1033 supports an end of the bearing cartridge 1090,e.g., an exterior surface of the sleeve 1092 of the bearing cartridge1090 is bonded in the tube portion 1033, e.g., using adhesive. Also, thestator component 1045 is provided (e.g., bonded using an adhesive) alongthe exterior surface of the sleeve 1092.

A rotor cap 1060 (supporting the magnet 1050 and impeller 1080) isprovided to the rotor 1070 rotatably supported by bearings 1094, 1095within the bearing cartridge 1090. In this example, the magnet 1050 isprovided along an interior surface of the rotor cap 1060 and a peg orpin 1061 is provided to the upper wall of the rotor cap to retain theimpeller 1080. In the illustrated example, the peg 1061 provides adiameter (e.g., 3-5 mm, e.g., 4 mm) that is larger than a diameter ofthe rotor 1070 (e.g., 1-3 mm, e.g., 2 mm). The recess provided by theoutwardly and upwardly extending wall portions 1035, 1036 of thebearing-housing structure 1030 allow the rotor cap, magnet and statorcomponent to at least be partially nested within the bearing housingstructure to provide a lower profile blower.

The top cover 1022 cooperates with the bearing-housing structure 1030 todefine the volute 1039 that directs air towards the outlet 1025. Asillustrated, the top cover 1022 includes a cylindrical, separating wallor baffle 1022(1) and together with the stepped configuration of the endportion 1037 separate the volute 1039 into two regions, i.e., a highspeed airpath region 1070(1) and a low speed airpath region 1070(2),e.g., to minimize pressure pulsations and/or acoustic noise.

A seal 1095 (e.g., constructed of silicone rubber or other suitablematerial) may be provided between the bearing-housing structure 1030 andthe top and bottom covers 1022, 1024, e.g., to provide a seal along thevolute, support a PCB, and/or provide wire grommet for guiding PCBwires.

Further details and examples of aspects of the blower 1000, e.g., highspeed and low speed airpath regions, are disclosed in PCT PublicationNo. WO 2011/062633, which is incorporated herein by reference in itsentirety.

FIG. 148 shows another blower example similar to that shown in FIGS. 139to 142 . In contrast, the bottom cover 1024 of the blower 1000 providesa tube portion 1024(1) supports an end of the bearing cartridge 1090. Inthis example, the bearing-housing structure 1030 includes a centralopening that allows the rotor cap 1060, magnet 1050 and stator component1045 to at least be partially nested within the bearing housingstructure. FIGS. 149 and 150 show such blower 1000 mounted within thecasing 1012 of a PAP device 1015 according to an example of the presenttechnology. As illustrated, the inlet 1013 and outlet 1014 are providedon opposite ends of the casing,

FIGS. 143-147 and 151 show alternative examples of blowers including anoutlet that is tangential to the inlet. In FIG. 143 , the impeller 1180is supported along the upper wall of the rotor cap 1160. The rotor cap1160 (also supporting magnet 1150) is provided to the rotor 1170rotatably supported by the bearing cartridge 1190. In this example, thehousing 1120 includes a tube portion 1133 that supports the bearingcartridge 1190. The stator component 1145 is provided along the exteriorsurface of the bearing cartridge 1190. A stationary component 1130 isprovided within the housing 1120 to provide a disk 1134 (e.g., toprevent blade pass tonal noise) and define the volute for directing airtowards the outlet 1125.

In FIG. 144 , the bearing-housing structure 1230 is integrated with thestator component 1245 of the motor, e.g., by overmolding, to form aone-piece structure. The bearing-housing structure 1230 provides a tubeportion 1233 that supports bearings 1295 that rotatably support therotor 1270. The rotor cap 1260 is provided to one end of the rotor 1270and supports magnet 1250 in an operative position with respect to thestator component 1245 integrated with the bearing-housing structure1230. The impeller 1280 is provided to the opposite end of the rotor1270.

In FIG. 145 , the bottom cover 1324 of the housing is structured todefine the volute 1339 for directing air towards the outlet 1325. Thebottom cover 1324 also supports the bearing-housing structure 1330including a tube portion 1333 that supports the bearing cartridge 1390and a disk 1334. The stator component 1345 is provided along theexterior surface of the bearing cartridge 1390. The rotor cap 1360(supporting magnet 1350) is provided to one end of the rotor 1370 andthe impeller 1380 is provided to the opposite end of the rotor 1370.

FIGS. 146 and 147 show alternative examples of a bearing-housingstructure 1430 including one or more walls defining the volute 1439 fordirecting air towards the outlet 1425. Similar to examples describedabove, the impeller 1480 is provided along the upper wall of the rotorcap 1460, and the motor components (e.g., rotor cap, magnet and statorcomponent) are at least partially nested within the bearing housingstructure.

In FIG. 151 , the housing 1520 provides a generally annular-shaped inlet1523 and an outlet 1525 that is tangential to the inlet. The innerhousing part 1529 supports the bearing cartridge 1590 adapted torotatably support the rotor 1570. The rotor cap 1560 (supporting themagnet 1550 and impeller 1580) is provided to an end portion of therotor 1570. The stator component 1545 is provided along the exteriorsurface of the bearing cartridge 1590. In an example, the gap A betweenthe impeller 1580 and an upper part of the housing 1520 and the gap Abetween the impeller 1580/rotor cap 1560 and a lower part of the housing1520 is about 0.75 to 1.0 mm.

Impeller

In the illustrated example, as shown in FIGS. 14 and 15 , the impeller180 (also referred to as a double-shrouded impeller oralternating-shroud impeller) includes a plurality of continuously curvedor straight blades 182 sandwiched between a pair of disk-like shrouds184, 186. As illustrated, the blades curve in towards the hub having anS-like shape. The shape is designed to reduce vortex shedding. Also, theshrouds may not fully cover the top and bottom surfaces of the blades.The lower shroud 186 incorporates the hub 185 that is adapted to receivethe rotor cup 160, e.g., press-fit. Also, the impeller includes atapered configuration wherein the blades taper towards the outer edge.In an example, the impeller may be constructed of a plastic material,e.g., Lexan®. Further details of impellers are disclosed in WO2007/048206 A1, which is incorporated herein by reference in itsentirety.

In certain examples, the impeller blades 182 may be curved in agenerally clockwise direction. In an alternative example, the impellerblades 182 may be curved in a generally counter-clockwise direction.

In an alternative example, as shown in FIGS. 93 and 94 , a bottomshrouded impeller (i.e., bottom surface of blades 182 covered by a lowershroud 186) may be used, e.g., to help prevent impeller lifting off theshaft or rotor in use. FIG. 93 illustrates an example of the S-likeshape of the blades 182. The slight S-shape at the beginning of eachblade is a result of having the blades attach to the hub and not blockthe inflow.

As shown in FIGS. 95 and 96 , the leading edges 182(1) of the impellerblades 182 may have a sweptback configuration in that the leading edgesof the impeller blades are slanted or angled back inwards in theopposite direction of the flow. This configuration provides a longerblade length providing higher pressures, reduces drag at the impellerleading edge and/or causing streamwise vortices to be formed in the flowpath which can delay the flow separation, thus reducing drag and flowoscillations and increased efficiency. In an example, the blade heightat the leading edge may increase at an angle of about 10-50°, e.g., 20°,along the length of the blade to a point about ¼ of the length of thevane.

Alternatively, as shown in FIGS. 97 and 98 , the impeller blades 182 mayhave a leading edge 182(1) that is normal to the flow direction as inconventional impellers. It should be appreciated that the blade and vaneangles may be selected for different conditions and/or performanceoptimizations.

The impeller may have a rotor portion integrated therein. The rotorportion is configured to interact with the magnet by serving as a pathfor the magnetic flux to cause rotation of the impeller throughinteraction with the stator. The rotor component of the impeller may bea single-piece construction or it may be formed as an cylindrical insertof magnetic steel within a non-ferrous structure of plastic or othernon-magnetic material that could be the impeller itself; such an insertcould be attached by various methods including overmolding, aninterference press fit, or adhesive bonding. The insert or ring offerrous material would retain the impeller on the stator in use. In anexample, there is no fastening of the impeller to the stator—theimpeller 180 and rotor cap 160 are retained by a magnetic attractionbetween the magnet 150 (coupled to the interior surface of the rotorcap) and the stator assembly 145.

FIGS. 113 to 115 show impellers according to alternative examples of thepresent technology. In FIG. 113 , the impeller 480 includes a largernumber of blades 482 than examples disclosed above, e.g., 22 blades, toreduce noise by reducing tonal frequencies. However, it should beappreciated that more or less blades are possible. Also, each blade 482includes a curved configuration and is curved in a generally clock-wisedirection, e.g., to reduce broadband and tonal noise. However, as shownin FIG. 114 , the blades 482 of the impeller 480 may be curved in theopposite direction, i.e., curved in a generally counter-clock-wisedirection. FIG. 115 shows another example of an impeller 480 including11 blades 482 with each blade curved in a generally counter-clock-wisedirection.

In FIGS. 113 and 114 , every other blade includes a top edge 482(1)along its length that tapers towards the outer edge. The remainingblades in FIGS. 113 and 114 include a top edge 482(2) that graduallyincreases in height from the hub before tapering towards the outer edge.In FIG. 115 , all the blades include a top edge 482(1) along its lengththat tapers towards the outer edge. However, it should be appreciatedthat other blade configurations are possible.

FIG. 113 shows a rotor cap 460 along with rotor 470 provided to the hub485 of the impeller 480, e.g., with a press-fit.

Exemplary Dimensions

In an example, as shown in FIG. 16 , D1 may be about 50-70 or more,about 60-65 mm, e.g., about 62.8 mm, D2 may be about 8-13 mm or more,e.g., about 10.4 mm, D3 may be about 15-20 mm or more, e.g., about 18.4mm, D4 may be about 15-25 mm or more, e.g., about 23.2 mm, D5 may beabout 20-30 mm, e.g., about 27 mm, and D6 may be about 20-25 mm, e.g.,about 21 mm. It is to be understood that these dimensions and ranges aremerely exemplary and other dimensions and ranges are possible dependingon application. For example, ranges that vary from those provided +/−10%or more may be suitable for particular applications.

PAP Systems

Certain examples relate to PAP systems that comprise a blower asdescribed herein. In certain examples, the blower may be mounted on thepatient's head (e.g., on the crown of the patient's head or on the frontportion of a patient's head), patient's arm, chest, or other body part,in or beside a pillow, in a scarf-like arrangement, incorporated intoclothing, attached to a bed or bed head, etc. However, the PAP systemmay utilize the blower described herein in a more conventional PAPdelivery device, e.g., of the type that includes a chassis or enclosurethat is intended to rest on the user's bedside table.

While the present disclosure has been described in connection withcertain examples, it is to be understood that the present disclosure isnot to be limited to the disclosed examples, but on the contrary, isintended to cover various modifications and equivalent arrangements. Forexample, while the blower has been described in relation to an axialblower, the blower could also be configured as a tangential blower.Furthermore, the blower is described for use in a headworn PAP system,but it could also be used in conjunction with a more conventional PAPsystem that includes a separate flow generator that is not mounted onthe user's head or body. Also, the various examples described herein maybe implemented in conjunction with other examples, e.g., aspects of oneexample may be combined with aspects of another example to realize yetother examples. Further, each independent feature or component of anygiven assembly may constitute an additional example. In addition, whilethe present disclosure has particular application to patients who sufferfrom OSA, it is to be appreciated that patients who suffer from otherillnesses (e.g., congestive heart failure, diabetes, morbid obesity,stroke, bariatric surgery, etc, or combinations thereof) may derivebenefit from the teachings of this disclosure. Moreover, the teachingsof this disclosure have applicability with patients and non-patientsalike in non-medical applications.

What is claimed is:
 1. A blower, comprising: a housing including aninlet and an outlet; a bearing-housing structure provided to the housingand adapted to rotatably support a rotor; a motor provided to thebearing-housing structure and adapted to drive the rotor; and animpeller provided to the rotor, wherein the bearing-housing structureincludes a bearing shaft having a bearing surface that rotatablysupports the rotor, the bearing shaft providing only a single bearing ofthe non-ball bearing type for the rotor.
 2. A blower according to claim1, wherein the blower provides pressurized air up to a maximum ofapproximately 8 cm H₂O.
 3. A blower according to claim 1, wherein theblower is operated at a speed of approximately 15,000 rpm.
 4. A bloweraccording to claim 1, wherein the inlet and the outlet are co-axiallyaligned.
 5. A blower according to claim 1, wherein the housing includesa top cover providing the inlet and a bottom cover providing the outlet.6. A blower according to claim 5, wherein the bottom cover includes aplurality of stator vanes to direct airflow.
 7. A blower according toclaim 1, wherein the bearing-housing structure includes an annular diskthat substantially aligns with or extends radially beyond an outer edgeof the impeller to provide a shielding function.
 8. A blower accordingto claim 1, wherein the bearing-housing structure is constructed of alow friction lubricious material.
 9. A blower according to claim 8,wherein the bearing-housing structure is constructed of sintered bronzeor a polyamide-imide resin.
 10. A blower according to claim 1, whereinthe motor includes a stator assembly, a magnet, and a rotor cap, therotor cap including an interior surface that supports the magnet and anexterior surface that supports the impeller, and wherein the rotor capis engaged with the rotor such that the stator assembly acts on themagnet to cause spinning movement of the rotor cap and hence theimpeller in use.
 11. A blower according to claim 1, wherein the motor isat least partially nested within the impeller.
 12. A blower according toclaim 1, wherein the impeller is retained on the rotor by magneticretention.
 13. A blower according to claim 1, wherein the impeller isnot directly fastened to the rotor.
 14. A blower according to claim 13,wherein the impeller is supported on the rotor by a rotor cap.
 15. Ablower, comprising: a housing including an inlet and an outlet; abearing-housing structure provided to the housing and adapted torotatably support a rotor; a motor provided to the bearing-housingstructure and adapted to drive the rotor; and an impeller provided tothe rotor, wherein the motor is at least partially nested within theimpeller.
 16. A blower, comprising: a housing including an inlet and anoutlet; a bearing-housing structure provided to the housing and adaptedto rotatably support a rotor; a motor provided to the bearing-housingstructure and adapted to drive the rotor; and an impeller provided tothe rotor, wherein the impeller is retained on the rotor by magneticretention.
 17. A blower according to claim 16, wherein the impeller isnot directly fastened to the rotor.
 18. A blower according to claim 17,wherein the impeller is supported on the rotor by a rotor cap.